efficient workflow systems for new composite applications

Eff ic ient Workflow Systems for

New Composite Appl icat ions

5 t h I n t e r n a t i o n a l C o m p o s i t e C o n fe re n c e 2 0 1 9

Julien Sellier

Messe Stuttgart Congress West – 12th September 2019

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NOT to be modified, reused, copied or distributed in any way without permission of STRUCTeam Ltd

S T R U C Te a m M a r ke t s

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Composite

Application

Development

Across

Sectors

Renewables

Marine

Civil and Structural Engineering

Automotive

Industrial and

Chemicals

Oil & Gas

S T R U C Te a m S e r v i c e s fo r S t r u c t u ra l

A d va n c e d M a t e r i a l s – S i n c e 2 0 1 0

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CME Services Engineering Services:Material

Design

Manufacture

Supply Chain

Expert Witness

Advisory Services

Training and Experience Development Services

Raw Material

Manufacturer

Intermediate Material

Manufacturer Part Manufacturer O.E.M

Adopting Advanced Materials

Efficient Workflow System

Workflow Case Studies

Conclusion

A ge n d a

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Adopting Advanced Materials

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A d va n c e d M a t e r i a l D e m a n d s

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• Aerospace• Wind• Auto the big question• Others

?

3x

2x}?

Market Size

(Source: STRUCTeam Ltd, Carb Consult, others)

Reinforcements only

A d va n c e d M a t e r i a l D e m a n d s

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(Source: STRUCTeam Ltd, Owens Corning, others)

Reinforcements only

M a t u re S e c t o r

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Backlog Year

(Source: STRUCTeam Ltd, JEC, others)

E m e rg i n g S e c t o rs

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InfrastructureComponents

or system

Infrastructure,Components

Super StructuresInfrastructure,Components,Rolling Stock

Including Thermoplastics

Note: Economics needs to adopt / add up for Business Case & Cost benefits

(Source: STRUCTeam Ltd, JEC, others)

A C o m p l ex S u p p l y C h a i n

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Raw Material

Manufacturer

Intermediate Material

Manufacturer Part Manufacturer O.E.M

OlinDowAksa

CPIC FibreglassToray

ArkemaOwens Corning

ExxonMobil

GoldwindGE

BMWSiemens Gamesa

Airbus

SMEs

A p p l i c a t i o n Re q u i re m e n t s

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Mature Sector Emerging Sector

Marine Wind Energy Aerospace Civil Oil & Gas Shipping Rail

Material

Thermal Durability u u u u u u

Impact Resistance u u u u

High Heat u u

Chem. Corrosion

Resistance u u u

Fire Retardant u u u u

Insulation Properties u u

Design

Design Freedom u u u u u u

High Strength to

weight ratio u u u u u

Specific Stiffness u u u u

Sound Damping u u u

Manufacturing

Light Weight u u u u u u

Design for

Manufacturing

Adaptationu u u u

Supply Chain

Cost u u u u u u u

Price Index u u u u

Evo l u t i o n a r y v s . R a d i c a l

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2 approaches to achieve material adoption

¤ Evolutionary (normal) approach

¤ Radical approach

Evolutionary vs. Radical

Mature Market Emerging Market

Composite Leaf Spring, Corvette Increased Advanced Materials BOM,

Airbus 787 Dreamliner

Pushing the limits on performance with

adoption of materials, America’s Cup sailing vessels

Tra d i t i o n a l M a t e r i a l s Wo r k f l o w

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Is it really easy to adopt?

Materials

Process Design

Material Considerations

A d o p t i n g A d va n c e d M a t e r i a l s

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Process Considerations

A d o p t i n g A d va n c e d M a t e r i a l s

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Wet lamination Press Infusion

PultrusionPrepreg/Resin Film

InfusionAutomation

Design Tool Considerations

A d o p t i n g A d va n c e d M a t e r i a l s

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A d o p t i n g A d va n c e d M a t e r i a l s

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Materials

Process Design

Efficient Workflow

Eff ic ient Workflow System

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Te c h n o l o g y Re a d i n e s s L e ve l s ( T R L )

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Nasa

A d va n c e d M a t e r i a l s Wo r k f l o w S y s t e m

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Commercial Feasibility

Concept Design

Detail Design

Prototype

Preproduction

Serial Production

• Market Gap Analysis• Business Case Analysis

• Preliminary Design• Technology Selection• DFMEA

• Detailed Design Analysis• Tooling Analysis• PFMEA

• Material Qualification• Manufacturing Documentation• Supply Chain Management

• Null Series Evaluation• Part Acceptance Testing

• QM / QA Documentation• Certification Liaison

Cost Benefit Analysis

TRL 1 - 3

TRL 9

TRL 7 - 8

TRL 5 - 6

TRL 4

Critical Review Meeting

Workflow Case Studies

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C i v i l & I n f ra s t r u c t u re

N e t w o r k R a i l Pe d e s t r i a n B r i d ge

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End User Need

¤ Safety

¤ Low maintenance

¤ Low setup costs

¤ Reduced weight

¤ Ease of manufacture

¤ Ease of assembly

¤ Lower OPEX

W i n d E n e rg y & Re n e w a b l e s

P U L LW i n d

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End User Need

¤ Reduced weight

¤ Lower CAPEX

¤ Lower OPEX

¤ Improved cycle times

¤ Improved performance

¤ Ease of manufacture

O i l & G a s

B e l l e v i l l e S p r i n g

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End User Need

¤ Material selection suited

for mass production

¤ Improved fatigue

capabilities

¤ Corrosion resistance

¤ Abrasion resistance

¤ High temp. performance

¤ Weight reduction

¤ Simplified assembly

Conclusion

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The demand for the adoption of advanced materials is on the rise and

requires a suitable workflow system to achieve this

2 Approaches possible;

¤ Evolutionary Mature Market

¤ Radical Emerging Market

Focus on combined workflow methods considering;

¤ Materials

¤ Processes vs. Supply Chain and Commercial Reality

¤ Design

For improved workflow efficiency and other application benefits

C o n c l u s i o n

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Thank you for your attention

Questions?

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Julien Sellier

Julien.Sellier@structeam-ltd.com

STRUCTeam

www.structeam-ltd.com

+44 (0)1983 240534